ECONOMIC AND PRODUCT DESIGN

CONSIDERATIONS IN MACHINING
• Machinability
• Tolerances and Surface Finish
• Selection of Cutting Conditions
• Product Design Considerations in Machining
 Machinability
Relative ease with which a material (usually a
metal) can be machined using appropriate
tooling and cutting conditions
• Depends not only on work material
• Type of machining operation, tooling, and
cutting conditions are also important factors
 Machinability Criteria in Production
• Tool life – how long the tool lasts for the given
work material
• Forces and power – greater forces and power
mean lower machinability
• Surface finish – better finish means better
machinability
• Ease of chip disposal – easier chip disposal
means better machinability
 Machinability Testing
• Most tests involve comparison of work
materials
– Performance of a test material is measured
relative to a base material
– Relative performance is expressed as a
machinability rating (MR)
– MR of base material = 1.00 (100%)
– MR of test material > 1.00 (100%) means better
machinability
 Machinability Tests
• Tool life (most common test)
• Tool wear
• Cutting force
• Power required in the operation
• Cutting temperature
• Material removal rate under standard test
conditions
 Mechanical Properties that
Affect Machinability
• Hardness
– High hardness means abrasive wear increases so
tool life is reduced
• Strength
– High strength means cutting forces, specific
energy, and cutting temperature increase
• Ductility
– High ductility means tearing of metal as chip is
formed, causing chip disposal problems and poor
surface finish
 Tolerances and Surface Finish
in Machining
• Tolerances
– Machining provides high accuracy relative to most
other shape-making processes
– Closer tolerances usually mean higher costs
• Surface roughness in machining is determined
by:
– Geometric factors of the operation
– Work material factors
– Vibration and machine tool factors
 Geometric Factors
• Machining parameters that determine surface
geometry:
– Type of machining operation, e.g., milling vs.
turning
– Cutting tool geometry, especially nose radius
– Feed
• The surface geometry that would result from
only these factors = "ideal" or "theoretical"
surface roughness
 Effect of
Nose Radius
Effect of Feed
Effect of End
Cutting Edge
Angle
 Ideal Surface Roughness


2
Ri f
32NR

where Ri = theoretical arithmetic average surface

roughness; f = feed; and NR = nose radius
 Work Material Factors
• Built-up edge effects
• Damage to surface caused by chip
• Tearing of surface when machining ductile
materials
• Cracks in surface when machining brittle
materials
• Friction between tool flank and new work
surface
Effect of Work Material Factors
 To Predict Actual Surface Roughness
• First compute ideal surface roughness value
• Then multiply by the ratio of actual to ideal
roughness for the appropriate class of work
material
Vibration and Machine Tool Factors
• Related to machine tool, tooling, and setup:
– Chatter (vibration) in machine tool or cutting tool
– Deflections of fixtures
– Backlash in feed mechanism
• If chatter can be eliminated, then surface
roughness is determined by geometric and
work material factors
 How To Avoid Chatter (Vibration)
• Add stiffness and/or damping to setup
• Operate at speeds that avoid cyclical forces
with frequencies close to natural frequency of
machine tool system
• Reduce feeds and depths to reduce forces
• Change cutter design to reduce forces
• Use a cutting fluid
 Selection of Cutting Conditions
• One of the tasks in process planning
• For each operation, decisions must be made
about machine tool, cutting tool(s), and
cutting conditions
• These decisions must give due consideration
to workpart machinability, part geometry,
surface finish, and so forth
• Cutting conditions: speed, feed, depth of cut,
and cutting fluid
 Selecting Depth of Cut
• Depth of cut is often predetermined by
workpiece geometry and operation sequence
– In roughing, depth is made as large as possible to
maximize material removal rate, subject to
limitations of horsepower, machine tool and setup
rigidity, and strength of cutting tool
– In finishing, depth is set to achieve final part
dimensions
 Determining Feed
• In general: feed first, speed second
• Determining feed rate depends on:
– Tooling – harder tool materials require lower feeds
– Roughing or finishing - Roughing means high feeds,
finishing means low feeds
– Constraints on feed in roughing - Limits imposed
by cutting forces, setup rigidity, and sometimes
horsepower
– Surface finish requirements in finishing – select
feed to produce desired finish
 Optimizing Cutting Speed
• Select speed to achieve a balance between
high metal removal rate and suitably long tool
life
• Mathematical formulas are available to
determine optimal speed
• Two alternative objectives in these formulas:
1. Maximum production rate
2. Minimum unit cost
 Maximum Production Rate
• Maximizing production rate = minimizing
cutting time per unit
• In turning, total production cycle time for one
part consists of:
1. Part handling time per part = Th
2. Machining time per part = Tm
3. Tool change time per part = Tt/np , where np =
number of pieces cut in one tool life
 Maximum Production Rate
Total time per unit product for operation:

Tc = Th + Tm + Tt/np

Cycle time Tc is a function of cutting speed

Cycle Time vs. Cutting Speed
 Minimizing Cost per Unit
• In turning, total production cycle cost for one
part consists of:
1. Cost of part handling time = CoTh , where Co =
cost rate for operator and machine
2. Cost of machining time = CoTm
3. Cost of tool change time = CoTt/np
4. Tooling cost = Ct/np , where Ct = cost per cutting
edge
 Minimizing Unit Cost
Total cost per unit product for operation:

Cc = CoTh + CoTm + CoTt/np + Ct/np

Again, unit cost is a function of cutting speed,

just as Tc is a function of v
Unit Cost vs. Cutting Speed
Comments on Machining Economics
-I
• As C and n increase in Taylor tool life
equation, optimum cutting speed should be
reduced
– Cemented carbides and ceramic tools should
be used at speeds significantly higher than for
HSS
• vmax is always greater than vmin
– Reason: Ct/np term in unit cost equation
pushes optimum speed to left in the plot of Cc
vs. v
Comments on Machining Economics -
II
• As tool change time Tt and/or tooling cost Ct
increase, cutting speed should be reduced
– Tools should not be changed too often if either
tool cost or tool change time is high
– Disposable inserts have an advantage over
regrindable tools because tool change time is
lower
 Product Design Guidelines in
Machining - I
• Design parts that need no machining
– Use net shape processes such as precision casting,
closed die forging, or plastic molding
• If not possible, then minimize amount of
machining required
– Use near net shape processes such as impression
die forging
 Product Design Guidelines in
Machining - II
• Reasons why machining may be required:
– Close tolerances
– Good surface finish
– Special geometric features such as threads,
precision holes, cylindrical sections with high
degree of roundness
 Product Design Guidelines in
Machining - III
• Tolerances should be specified to satisfy
functional requirements, but process
capabilities should also be considered
– Very close tolerances add cost but may not add
value to part
– As tolerances become tighter, costs generally
increase due to additional processing, fixturing,
inspection, sortation, rework, and scrap
 Product Design Guidelines in
Machining - IV
• Surface finish should be specified to meet
functional and/or aesthetic requirements
– However, better surface finish generally increases
processing cost by requiring additional operations
such as grinding or lapping
 Product Design Guidelines in
Machining - V
• Machined features such as sharp corners,
edges, and points should be avoided
– They are difficult to machine
– Sharp internal corners require pointed cutting
tools that tend to break during machining
– Sharp corners and edges tend to create burrs and
are dangerous to handle
 Product Design Guidelines in
Machining - VI
• Machined parts should be designed so they
can be produced from standard stock sizes
• Example: rotational parts with outside
diameters equal to standard bar stock
diameter
 Product Design Guidelines in
Machining - VII
• Select materials with good machinability
– As a rough guide, allowable cutting speed and
production rate correlates with machinability
rating of a material
– Thus, parts made of materials with low
machinability take longer and cost more to
produce
 • Design machined parts with features that can
be produced in a minimum number of setups
• Example: Design part with geometric features
that can be accessed from one side of the part

Figure 24.6 – Two parts with similar hole features:

(a) holes that must be machined from two sides, requiring two setups,
(b) and holes that can all be machined from one side
 Product Design Guidelines in
Machining - VIII
Machined parts should be designed with
features that can be achieved with standard
cutting tools
• Avoid unusual hole sizes, threads, and
features requiring special form tools
• Design parts so that number of individual
cutting tools needed is minimized